Wall Structure Of Large-Sized Refrigerated Storage And Construction Method Thereof

ABSTRACT

A method for constructing a wall structure, which comprises an interior wall board, an exterior wall board and a skeleton positioned between the interior wall board and the exterior wall board. The method for construction the wall comprises the following steps: A. building the wall skeleton; B. mounting a color steel plate on the outer surface of the skeleton to form an exterior wall board of the wall; C. painting the polyurethane spraying material on the exterior wall board layer by layer for multiple times, and reserving a pouring apace at a distance of 40 to 80 mm from the installation position of a interior wall board; and D. taking the color steel plate of the interior wall as a mould plate and pouring space at the color steel plate of the interior wall to form the interior wall board of the wall.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a divisional of U.S. Application Ser. No. 13/262,242 filed on Sep. 30, 2011, which application is a national phase entry under 35 U.S.C. §371 of International Application No. PCT/CN2010/071436 and filed Mar. 30, 2010, which claims priority from CN 200910038383.0 filed Apr. 3, 2009, all of which are hereby incorporated herein by reference.

FIELD OF THE INVENTION

The present invention relates to building structure and construction, and more particularly, to a wall structure of a large-sized refrigerated storage and a construction method thereof.

BACKGROUND OF THE INVENTION

Currently, the wall construction of large-sized refrigerated storage can be divided into three types: the first kind is a refrigerated storage of Reinforced Concrete Frame Structure by applying the insulation to the outside and/or the inside of the reinforced concrete frame being erected; the second kind is a combined refrigerated storage constructed by jointing connection of combination library boards; the third kind is a refrigerated storage of steel frame structure by applying the insulation to the outside and/or the inside of the steel frame of the wall construction of refrigerated storage being erected by steel totally.

Though the first type of the refrigerated storage aforementioned has a good sealing and thermal insulation, it takes a long construction period, and thus cost too much and is not flexible enough; the second type of the refrigerated storage takes a short construction period, but it is easy to produce a crack on the joint of the library boards in a long-term process of temperature variation, and this “cold running” problem is particularly serious in a large-sized refrigerated storage with vast proportions; in order to construct this refrigerated storage with a steel frame structure e of the third type aforementioned, it is the most important to dealt with the problem of the broken cold-bridge components inside and/or outside the wall structure and make sure of the Integration and the sealing of the insulation.

Hence, it is desired to provide an improved wall structure of a refrigerated storage by applying a construction method of the wall insulation to the wall structure to solve the above-mentioned problems and achieve a good performance.

SUMMARY OF THE INVENTION

Accordingly, an object of the present invention is to provide a wall structure of a large-sized refrigerated storage which is capable of providing strong sealing and insulation, having a structure of high strength and beautiful generous, and being nice to meet food hygiene requirements.

Another object of the present invention is to provide a method of construction wall of a large-sized refrigerated storage to shorten the construction period to be equivalent to the construction period of combined refrigerated storage.

To achieve the above-mentioned objects, the wall structure of a large-sized refrigerated storage comprises an interior wall board, an exterior wall board and a skeleton positioned between the interior wall board and the exterior wall board, a space formed between the interior wall board and the exterior wall board being filled with a polyurethane foam plastic; the skeleton which being constructed by vertical fixed steel columns and lateral fixed light steels having broken cold-bridge components fixed therein, each of said broken cold-bridge components having two ends being soldered to the light steels on both side of the skeleton respectively.

Preferably, the vertical fixed steel columns of the skeleton are situated at the exterior wall board or a high-temperature side in line, and the lateral fixed light steels of the skeleton are situated at the interior wall board as well as at the exterior wall board in parallel.

Preferably, each of said broken cold-bridge components is mainly consist of a solid cylindrical insulation rod being made of high impaction PP (polyethylene propylene as the main component) and two screws, each of said screws having one end thereof connecting to either end of the insulation rod and the other end thereof being soldered to the skeleton.

Preferably, the insulation rods positioned on the same level are perpendicular to the interior wall board and the exterior wall board, and a distance between the adjacent insulation rods ranges from 500 mm to 1000 mm. A reasonable distribution of the insulation rods is capable of strengthening the whole skeleton and ensuring the well-rounded broken cold-bridge of the wall.

Preferably, the interior wall board is a color steel plate, a stainless steel plate or a sandwich panel and the exterior wall board wall is a color steel plate, a stainless steel plate, a aluminum plate or a sandwich panel; the steel columns are C-shaped steels or channel steel columns and the light steels are angle steels or C-shaped steels” and a distance between the adjacent steel columns ranges from 2000 mm to 4000 mm. The wall of the refrigerated storage which resorts to a double-faced color steel plate, a stainless steel plate or a aluminum plate for the mounting to improve the characteristics of fire prevention and collision avoidance, is safe and reliable, beautiful generous, and nice to meet food hygiene requirements; the structure of the C-shaped steels or channel steel columns is strength enough to avoid the “cold running” problem produced by stress concentration of joints of the library boards in the process of installation, thus increase the age of the storage.

A method of construction wall of a large-sized refrigerated storage, comprising the steps of:

-   -   A. building the wall skeleton, each skeleton of the wall of the         refrigerated storage being connected reciprocally, so as to         forming an overall framework;     -   B. mounting a color steel plate, a stainless steel plate, a         aluminum plate or a sandwich panel on the outer surface of the         skeleton to form an exterior wall board of the wall of the         refrigerated storage by assembling the stainless steel plate,         the aluminum plate or the sandwich panel;     -   C. painting the exterior wall board with a polyurethane spraying         material layer by later for multiple times, and reserving a         pouring apace at a distance of 40 to 80 mm from the installation         position of a interior wall board; and     -   D. mounting a color steel plate, a stainless steel plate or a         sandwich panel of the interior wall board in order by taking a         color steel plate, a stainless steel plate or a sandwich panel         of the interior wall as a mould plate and pouring a polyurethane         spraying material into the pouring space at the color steel         plate, the stainless steel plate or the sandwich panel of the         interior wall and then mounting another color steel plate,         another stainless steel plate or another sandwich panel of the         interior wall board after the solidification of the polyurethane         spraying material and then pouring a polyurethane spraying         material again to form a interior wall board of the wall of the         refrigerated storage.

The construction method is simple, and takes a short construction period; with the special construction method, the interior wall which makes a color steel plate, a stainless steel plate, a sandwich panel and a foam into a unit by pouring and mounting a color steel plate, a stainless steel plate or a sandwich panel is solid and practical, and it has no gap between the color steel plate, the stainless steel plate and the foam, so as to protect the foam best for effectively preventing the escape of foaming agent and maintaining thermal conductivity at a stable level; the entirety, sealing and collision avoidance of the wall are good, and the age of polyurethane foam is prolonged.

Preferably, the step A further comprises steps of: building the skeleton with C-shaped steel columns and angle steels by providing a line of C-shaped steel columns situated at the exterior wall board or a high-temperature side, the distance between the adjacent steel columns being ranged from 2000 mm to 4000 mm; and providing a plurality of lateral fixed angle steels on the C-shaped steel columns being up, each broken cold-bridge component having one end thereof being soldered to the angle steel situated at the exterior wall board and the other end thereof being soldered to the angle steel situated at the interior wall board.

Preferably, the distance between the adjacent insulation rods of broken cold-bridge component positioned on the same level ranges from 500 mm to 1000 mm.

Preferably, the color steel plate, the stainless steel plate or the aluminum plate of the exterior wall board and the color steel plate, the stainless steel plate or the sandwich panel of the interior wall board are fixed to the angle steels of the skeleton by self-tapping screws or sealed type blind rivets in steps B and C.

Preferably, the spraying method of layer by layer for multiple times in step C comprises steps of:

-   -   taking the color steel plate, the stainless steel plate or the         sandwich panel of the interior wall with a thickness of the         polyurethane spraying material being 10 to 15 mm as a mould         plate for the first time of spraying;     -   forming a thickness of the polyurethane spraying material being         15 mm to 25 mm for the second time of spraying;     -   forming a thickness of the polyurethane spraying material being         25 mm to 35 mm for the third time of spraying, and taking the         thickness as the model for each spraying after that until         producing a distance of 40 nun to 80 mm from the interior wall         board; and each interval between two sprayings being more than 5         minutes.

Compared with the prior art, the wall structure of a large-sized refrigerated storage for the lapping plate according to the present invention brings a lot of following advantageous effects:

(1) the quick spraying construction method of a refrigerated storage applied to a light steel structure is capable of providing a better insulation performance and saving energy 10% in comparison with the combined storage;

(2) the method of construction wall of a refrigerated storage is quick and efficient that the construction period it takes is only one half of that of the civil storage and equal to that of the combined storage;

(3) the wall and the refrigerated storage which resorts to a double-faced color steel plate, a stainless steel plate or a aluminum plate for the mounting to improve the characteristics of fire prevention and collision avoidance, is safe and reliable, beautiful generous, and nice to meet food hygiene requirements;

(4) the wall has a lot of characteristics such as entirety, seamless and good insulation which are equal to those of a civil storage;

(5) the structure of light steel is strength enough to avoid the “cold running” problem produced by stress concentration of joints of the library boards, thus prolong the age of the storage.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a longitudinal sectional view of a wall structure of a large-sized refrigerated storage according to the present invention;

FIG.2 is a top plan view of a wall structure of a large-sized refrigerated storage according to the present invention;

FIG. 3 is a view of a distribution of insulation rods according to the present invention;

FIG. 4 is a flow chart of method of construction wall according to the present invention.

DETAILED DESCRIPTION OF ILLUSTRATED EMBODIMENTS

Various preferred embodiments of the invention will now be described with reference to the figures, wherein like reference numerals designate similar parts throughout the various views.

FIGS. 1-3 illustrate an embodiment of a wall structure of a large-sized refrigerated storage according to the present invention. Referring to FIGS. 1-3, the wall structure of a large-sized refrigerated storage comprises an interior wall color steel plate 1 as an interior wall board, an exterior wall color steel plate 2 as an exterior wall board and a skeleton positioned between the interior wall color steel plate 1 and the exterior wall color steel plate 2. A space formed between the interior wall color steel plate I and the exterior wall color steel plate 2 is filled with polyurethane foam plastic 7. The skeleton is constructed by vertical fixed steel columns 6 and lateral fixed angle steels 5. The vertical fixed steel columns 6 of the skeleton are C-shaped steels which situated at the exterior wall board or one side of the high-temperature wall board 2 in line, and the lateral fixed angle steels 5 of the skeleton are situated at the interior wall color steel plate 1 as well as at the exterior wall color steel plate 2 in parallel. In order to fix the angle steels 5 at the interior wall color steel plate 1 and at the exterior wall color steel plate 2, providing a plurality of broken cold-bridge components each connecting to the angle steels 5 at the interior wall color steel plate 1 and the angle steels 5 at the exterior wall color steel plate 2 which positioned on the same level as the steels 5 at the interior wall color steel plate 1. The addition of the broken cold-bridge components not only establish the whole skeleton structure, but also avoid the cool air in the refrigerated storage escaping. In the embodiment, the interior wall color steel plate 1 and the exterior wall color steel plate 2 are both made up of corrugated color steel plates, with the interior wall color steel plate 1 fixed on the angle steels 5 of the interior wall board and the exterior wall color steel plate 2 fixed on the angle steels 5 of the exterior wall board, and the polyurethane foam plastic 7 in the wall integrated with the interior wall color steel plate 1 and the exterior wall color steel plate 2, thus form a whole structure.

In the embodiment of the invention, alternatively, in order to strengthen the skeleton structure, the steel columns 6 are applied to on the interior wall color steel plate 1 as well as the exterior wall color steel plate 2. Two square-formed net frames each formed on either surface of the skeleton being contacted to the interior or exterior wall color steel plate 1, 2 is made up of a crossed welding of the C-shaped steels columns 6 of vertical arrangement and the angle steels 5 of lateral arrangement. The two square-formed net frames includes a interior net frame and a exterior net frame, and the angle steels 5 on the interior net frame is level with those on the exterior net frame. What's more, providing a plurality of broken cold-bridge components each connecting to the angle steels 5 at the interior wall color steel plate 1 and the angle steels 5 at the exterior wall color steel plate 2 which positioned on the same level as the steels 5 at the interior wall color steel plate 1 by welding to strengthen the skeleton structure further.

In the embodiment of the invention, the distance between the adjacent steel columns ranges from 2000 lnm to 4000 mm as required. In the case of meeting the limitation requirements, alternatively, the distance between the adjacent steel columns is 3000 mm.

Each of the broken cold-bridge components is mainly consist of a solid cylindrical insulation rod 3 being made of high impaction PP and two screws 4. In order to connecting the insulation rod 3 and the screw 4 quickly and conveniently, either end of the insulation rod 3 has a screwhole or a metal wire, and one end of the screw 4 is spinning to the screwhole or the metal wire of the insulation rod 3 when the other end of the screw 4 is connecting to the angle steel 5 by welding. Each of the angle steels 5 in the same level is connecting with a insulation rod 3, and the insulation rods 3 positioned on the same level are perpendicular to the interior wall board land the exterior wall board 2 essentially. According to the practical situation, the distance between the adjacent insulation rods 3 ranges from 500 mm to 1000 mm. In the embodiment of the invention, alternatively, the distance between the adjacent insulation rods 3 is 750 mm.

Referring to FIGS. 1-4, a method of construction wall of a large-sized refrigerated storage comprising the steps of:

-   -   A. building the wall skeleton, each skeleton of the wall of the         refrigerated storage being connected reciprocally, so as to         forming an overall framework;     -   B. mounting a exterior wall color steel plate 2 on the outer         surface of the skeleton to form an exterior wall board of the         wall of the refrigerated storage by assembling the exterior wall         color steel plate 2 using a sealed type blind rivet with         excellent water resistance;     -   C. painting the exterior wall color steel plate 2 with a         polyurethane spraying material layer by layer for multiple         times, and reserving a pouring apace at a distance of 40 to 80         mm from the installation position of a interior wall color steel         plate 1; and     -   D. mounting the interior wall color steel plates 1 in order by         taking a interior wall color steel plate 1 as a mould plate and         pouring a polyurethane spraying material into the pouring space         at the interior wall color steel plate 1, and then mounting         another color steel plate after the solidification of the         polyurethane spraying material and then pouring a polyurethane         spraying material again to form a interior wall board of the         wall of the refrigerated storage. The interior wall board can be         a stainless steel plate or a sandwich panel according to         different needs.

The step A further comprises the steps of: building the skeleton with C-shaped steel columns and angle steels 5 by providing a line of C-shaped steel columns 6 situated at the exterior wall board or a high-temperature side, the distance between the adjacent steel columns 6 being ranged from 2000 mm to 4000 mm; and providing a plurality of lateral fixed angle steels 5 on the C-shaped steel columns being up, each broken cold-bridge component having one end thereof being soldered to the angle steel 5 situated at the exterior wall color steel plate 2 and the other end thereof being soldered to the angle steel 5 situated at the interior wall color steel plate 1. The distance between the adjacent insulation rods of broken cold-bridge component positioned on the same level is 750 mm.

The spraying method of layer by layer for multiple times in the step C further comprises the steps of:

-   -   taking a first layer of the polyurethane spraying material of         the interior wall color steel plate 1 with the thickness being         10 mm to 15 mm as a mould plate at the first time of spraying,         and then painting a second layer with polyurethane spraying         material after the solidification of the first layer of the         polyurethane spraying material in 5 minutes;     -   forming a second layer of the polyurethane spraying material of         the interior wall color steel plate 1 with the thickness being         15 n1m to 25 mm, and then painting a third layer with         polyurethane spraying material after the solidification of the         second layer of the polyurethane spraying material in 5 minutes;         and     -   forming a third layer of the polyurethane spraying material of         the interior wall color steel plate 1 with the thickness being         25 mm to 35 mm, and taking the thickness of the third layer as         the model for each spraying after that until producing a         distance of 60 mm from the interior wall board.

The 60 mm space reserved to be used in the step D which comprises the steps of: mounting the interior wall color steel plates 1 by a sealed type blind rivet with excellent water resistance and pouring a polyurethane spraying material into the space between the interior wall color steel plate 1 being up and the foam layer of polyurethane spraying material by a pouring method of pouring the plates one after one: fastening a second plate to the first plate which has been pouring, and then pouring the second plate, until the polyurethane spraying material solidified, the interior wall color steel plate 1 and the instruction layer come into a unit that with no gap between the interior wall color steel plate 1 and the foam layer as well as the gaps between the adjacent interior wall color steel plates 1 are enclosing absolutely.

If the wall structure of refrigerated storage is applied in the storage as partition wall, the connection between the wall and the top of refrigerated storage also make thermal break dispose with heat insulation stick. The structure of the invention is simple, the strength of lightweight steel construction is high. The construction technology of the wall of refrigerated storage is quick and efficient, construction cycle only is the half of the one of civil engineering storage, close to combined type refrigerated storage; the out shield color-coated steel sheet plate, corrosion resistant plate or aluminum sheet and insulating layer are adhered to a unity by the flooding method, good performance of separate gas, crashworthiness; foam do not contact with air, the release and loss of foaming agent is slow, endure ageing; adopting thermal break structure dispose with heat insulation stick is safe and reliable, the construction is quick. 

What is claimed is:
 1. A method of construction wall of a large-sized refrigerated storage, wherein the method comprises the steps of: A. building the wall skeleton, each skeleton of the wall of the refrigerated storage being connected reciprocally, so as to forming an overall framework; B. mounting a color steel plate, a stainless steel plate, a aluminum plate or a sandwich panel on the outer surface of the skeleton to form an exterior wall board of the wall of the refrigerated storage by assembling the stainless steel plate, the aluminum plate or the sandwich panel; C. painting the exterior wall board with a polyurethane spraying material layer by layer for multiple times, and reserving a pouring apace at a distance of 40 to 80 mm from the installation position of a interior wall board; and D. mounting a color steel plate, a stainless steel plate or a sandwich panel of the interior wall board in order by taking a color steel plate, a stainless steel plate or a sandwich panel of the interior wall as a mould plate and pouring a polyurethane spraying material into the pouring space at the color steel plate, the stainless steel plate or the sandwich panel of the interior wall and then mounting another color steel plate, another stainless steel plate or another sandwich panel of the interior wall board after the solidification of the polyurethane spraying material and then pouring a polyurethane spraying material again to form a interior wall board of the wall of the refrigerated storage.
 2. The method of construction wall of a large-sized refrigerated storage according to claim 1, wherein said step A further comprises the steps of: building the skeleton with C-shaped steel columns and angle steels by providing a line of C-shaped steel columns situated at the exterior wall board or a high-temperature side, the distance between the adjacent steel columns being ranged from 2000 mm to 4000 mm; and providing a plurality of lateral fixed angle steels on the C-shaped steel columns being up, each broken cold-bridge component having one end thereof being soldered to the angle steel situated at the exterior wall board and the other end thereof being soldered to the angle steel situated at the interior wall board.
 3. The method of construction wall of a large-sized refrigerated storage according to claim 2, wherein the distance between the adjacent insulation rods of broken cold-bridge component positioned on the same level ranges from 500 mm to 1000 mm.
 4. The method of construction wall of a large-sized refrigerated storage according to claim 1, wherein the color steel plate, the stainless steel plate or the aluminum plate of the exterior wall board and the color steel plate, the stainless steel plate or the sandwich panel of the interior wall board are fixed to the angle steels of the skeleton by self-tapping screws or sealed type blind rivets in the steps of B and C.
 5. The method of construction wall of a large-sized refrigerated storage according to claim 1, wherein the spraying method of layer by layer for multiple times in the step C further comprises the steps of: taking a thickness of the polyurethane spraying material being 10 nun to 15 mm of the color steel plate, the stainless steel plate or the sandwich panel of the interior wall as a mould plate at the first time of spraying; forming a thickness of the polyurethane spraying material being 15 mm to 25 mm at the second time of spraying; forming a thickness of the polyurethane spraying material being 25 mm to 35 mm at the third time of spraying, and taking the thickness as the model for each spraying after that until producing a distance of 40 mm to 80 mm from the interior wall board; and each interval between two sprayings being not less than 5 minutes. 